Method and apparatus for improved firing of biomass and other solid fuels for steam production and gasification

ABSTRACT

A ground supported single drum power boiler is described combining a refractory lined and insulated V-Cell floor; refractory lined and insulated combustion chamber; integrated fuel chutes configured to pre-dry wet solid fuel; top mounted fuel bin; internal chamber walls; configurable combustion air systems; and a back pass with after-burner ports and cross flow superheaters. The boiler can be configured in pre-assembled modules to minimize the field construction time and cost. An alternative embodiment is adaptable as a gasifier.

This application is a Continuation of U.S. patent application Ser. No.13/851,883, filed Mar. 27, 2013, which claims priority from U.S. Prov.Pat. No. 61/616,211, filed Mar. 27, 2012, both of which are herebyincorporated by reference.

BACKGROUND OF THE INVENTION

Power boilers have long been used by industries and utilities to producesteam for power production and process requirements. These boilers comein many types and sizes but embodiments of the present invention are animprovement on bed-fired water tube boilers ranging in steam productionfrom 25 tons per hour to 300 tons per hour or more. The fuel may consistof bark, sawdust, wood chips, biomass trimmings, wood or other biomasspellets, urban waste, tire derived fuel (TDF), crushed coal, pet coke,sludge, fiber line rejects, straw based fuels, or other solid fuel, or acombination of fuels, and may have moisture content as high as 60%.These boilers are typically constructed of heavy wall steel tubes weldedside by side into wall panels that form the front, rear and side wallsof the boiler. The lower portion of this box forms the combustionchamber of the boiler and is sometimes called the furnace. The tubes aretypically 2½″ to 3″ in outside diameter with a wall thickness from 0.18″to 0.25″ and spaced apart 3″ to 4″ center to center. The gaps betweenthe tubes are filled with steel strips about ¼″ thick by the width ofthe gap. The entire panel is seal-welded air tight. The lower ends ofthe wall tubes are welded into larger diameter horizontal header pipesthat feed water to the walls. The tops of the wall tubes are alsoconnected to larger diameter horizontal collector pipes that carry thewater away from the walls to the steam drum, located at the top of theboiler. The front wall tubes are typically bent over to form the roof ofthe boiler and those tubes can terminate in a collector pipe or directlyto the steam drum. Similarly the rear wall tubes are typically bent tocreate a “bullnose” or “nose arch” to direct combustion gasses acrossthe convective section of the boiler and then terminate in a water drum,steam drum, or collector pipe at the top of the boiler. The top of thebullnose is usually at the elevation of the water drum. The convectivesection generally consists of a set of superheaters, located at the topof the boiler, that are heated predominantly through convection.Downcomer pipes connect the steam drum or water drum at the top of theboiler to the header pipes at the bottom of the tube walls and feedwater from the drum to the walls. The bottom of the boiler can be atravelling or vibrating grate, tilting grate, sloping grate, step grate,fluidized bed, or a stepped floor as described in U.S. patentapplication Ser. No. 12/557,085. Fuel enters the boiler through a chuteor chutes penetrating one or more walls of the boiler and may bebroadcast into the boiler by a fuel distributor, for example, asdescribed in U.S. patent application Ser. No. 12/406,035. The fuel fallsto the floor or grate where it is mixed with air and burns. The heatreleased by the burning fuel is absorbed by the wall tubes and heats thewater in the walls, where the water expands thermally and starts toboil. The heated and boiling water is less dense than the water in thedowncomer pipes, therefore a natural circulation is created with hotterwater rising in the tube walls and cooler water descending in thedowncomer pipes. The natural circulation is an inherent safety featureof these boilers as the circulation rate increases as more fuel isburned and more heat released in the combustion chamber.

As the water circulates from the steam drum, down through thedowncomers, up through the walls, and back to the steam drum, some ofthe water may boil but most of the boiling occurs in the steamgenerating bank, sometimes called the boiler bank. In older two drumboilers, the generating bank is a set of tubes connecting the bottom ofthe steam drum to the top of a water drum, sometimes called a mud drum,located up to thirty feet or so directly below the steam drum. There aregenerally hundreds of tubes connecting the two drums. The generatingbank is arranged so that hot gasses from the furnace flow across thetubes and heat the water circulating inside. About half of the tubes inthe generating bank of a two drum boiler are up flow tubes and theremainders are down flow tubes. The gas cools as it passes through thegenerating bank, therefore the first tubes the gas contacts (the fronttubes as the gas flow through a boiler is generally front to back) arehotter and more boiling occurs in those tubes. The boiling water is lessdense therefore the water circulates from the steam drum down throughthe rear tubes to the water drum then up through the front tubes back tothe steam drum. The steam drum is generally about half full of waterwith saturated steam being released at the surface. The steam goesthrough a set of moisture separators and then to the superheaters. Innewer single drum boilers there is no water drum, instead, thegenerating bank is fed by external (non-heated) downcomers from thesteam drum and the water circulates down the downcomers and back upthrough all of the generating bank tubes to the steam drum. Single drumboilers are less expensive to build because the drums, especially withhundreds of tube penetrations, are the most expensive components. Theyalso have other advantages including more flexible arrangements forlocating the steam drum.

Some boilers also have sets of tubes located just at the furnace exitand arranged to cross the boiler at the top of the combustion chamber.These are called screen tubes or screens, and are often arrayed asplatens in which several tubes are in close parallel arrangement, one ontop of another, extending from the front or rear wall of the boilerthrough the opposite wall. These platens are generally separated 12″-15″apart side to side and slope upward slightly to the other side of theboiler, or they may bend part way across the boiler and rise upvertically through the roof. The screen tubes are fed by external(non-heated) downcomers from the steam drum or water drum at their lowerend and relieved back to the steam drum at their upper end. Watercirculates from the steam drum or water drum through the screens andback up to the steam drum. The screens are located where the gasses arevery hot and absorb heat predominantly by radiation.

After the steam leaves the steam drum it goes to the superheaters. Theseare sets of tubes typically located at the top of the boiler, above thescreen tubes and in front of the generating bank. The superheatersincrease the temperature of the steam from the saturation temperature inthe steam drum to the final temperature desired for the process or powerplant. The superheater tubes are typically arranged as vertical platenswith up to a dozen tubes or more in close parallel arrangement front toback in each platen. There are many platens located across the width ofthe boiler with a spacing of 6″-15″ between platens. There arefrequently three or more superheater sections with external (unheated)connecting pipes and/or desuperheaters between the sections.Desuperheaters or attemporators control the final steam temperature byspraying water into the steam, or other means. The superheater tubesstart at the top of the boiler and drop vertically to just above thebullnose then run up and down a number of times before exiting backthrough the roof. The steam passes through the superheaters just oncetherefore the superheaters are not part of the boiler circulationcircuits.

After the combustion gasses exit the generating bank they typically flowthrough an economizer or an air heater. Economizers are tube bundleseither in cross flow or parallel flow to the gas stream through whichthe feedwater passes once and is heated and then goes to the steam drum.The feedwater flow is controlled to maintain the water level in thesteam drum. Feedwater makes up for the steam that is produced and exitsthe boiler. Upon entry into the drum, feedwater is baffled and mixeswith some of the water already within the steam drum to flow to thedowncomer pipes or downcomer tubes. This feedwater mixed zone is colderand has higher density, which provides the driving head for the naturalcirculation in the boiler. The economizer may be located immediatelyafter the generating bank (relative to the gas flow) integral with theboiler, or it may be located downstream from a tubular air heater or adust collector.

Some of these boilers are supported from underneath (ground supported)but most, especially larger boilers, are hung from the top and expanddownward as they heat up. A “hung” boiler typically may require a verystrong and expensive structure to support the boiler. One of the biggestproblems with current boiler design is the cost of erection. Smallerboilers are often supplied as a single unit or “package” boiler butlarger boilers typically may be erected in the field. This frequentlytakes much longer and may be much more expensive than anticipated,driving up the actual cost of the boiler. To partially address thisproblem, some boilers have been “modularized” to speed up theconstruction and reduce the risk associated with assembling the boilerin the field. Embodiments of present invention incorporate some specificmodular features to minimize the time and cost to erect the boiler.

Boilers as described above have been in use for many years and thetechnology is very mature, but they are very expensive and havesignificant operational limitations. Grate fired boilers and fluidizedbed boilers are limited in the temperatures they can tolerate in thelower furnace otherwise they will over heat the grate or sand bed. Theyalso do a poor job of mixing the combustion air and pyrolysis gassesabove the bed because the air flow arrangement is dictated by therequirements to cool the grate or fluidize the sand bend. This leaveslittle setup flexibility to improve combustion in the boiler. Mechanicalgrates suffer from poor reliability and fluidized bed boilers sufferfrom excessive sand erosion and sand agglomeration. These deficienciesare addressed with the introduction of stepped floor and fuel dryingchute technologies as described in U.S. patent application Ser. Nos.12/557,085 and 12/471,081 respectively, and provisional application61/522,939. Aspects of those technologies are incorporated intoembodiments of the present invention to improve the combustion ofdifficult to burn fuels.

SUMMARY OF THE INVENTION

It is an object of the invention to provide an improved boiler.

In some embodiments, fuel falls into one or more troughs at the bottomof the boiler, with each trough lined with an insulating material andrefractory material, so that the structure acts to reduce temperaturevariations in the furnace. In some embodiments, a fuel supply located ontop of the boiler along with a fuel feed system enables rapid andpreferably independent control of the supply of fuel to differentportions of the furnace. In some embodiments, the boiler is composed ofmodules that can be easily transported for assembly on site. In someembodiments, an array of chamber walls facilitates more efficient heattransfer from the combustion gases to improve steam generation.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter. It should be appreciated by those skilled in the art thatthe conception and specific embodiments disclosed may be readilyutilized as a basis for modifying or designing other structures forcarrying out the same purposes of the present invention. It should alsobe realized by those skilled in the art that such equivalentconstructions do not depart from the spirit and scope of the inventionas set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more thorough understanding of the present invention, andadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a sectional side view of a boiler in accordance with one ormore embodiments of the present invention;

FIG. 2 is a sectional front view of a boiler in accordance with one ormore embodiments of the present invention;

FIG. 3 is a sectional plan view cut through the boiler at Section A-A inFIG. 2 with the front of the boiler at the bottom;

FIG. 4 is an enlargement of the bottom of the boiler from FIG. 2 toillustrate some of the features and operation of the boiler; and

FIG. 5 is an enlargement of the bottom of the boiler from FIG. 1 toillustrate some of the features and operation of the boiler.

DETAILED DESCRIPTION

Various embodiments of the present invention include several novelfeatures that can significantly reduce the capital cost of the boilerwhile further improving the ability to burn difficult fuels.

The accompanying drawings are referred to in the following description.FIG. 1 is a sectional side view of the boiler and FIG. 2 is a sectionalfront view. FIG. 3 is a sectional plan view cut through the boiler atSection A-A in FIG. 2 with the front of the boiler at the bottom. FIGS.4 and 5 are enlargements of the bottom of the boiler from FIGS. 2 and 1respectively to illustrate some of the features and operation of theboiler. The numbers in this text refer to like numbers illustrated inthe drawings. Referring now to FIGS. 1 and 2, the combustion chamber 1is surrounded by a reinforced concrete foundation 2 that rises 15 to 20feet or more above the ground. Foundation walls 2 support front tubewall 3, left tube wall 25, right tube wall 26, and rear tube wall 27 ofthe boiler and intermediate foundation wall 7 supports intermediate tubewall 4 that separates the front pass 5 (the furnace) from back pass 6.Therefore in plan view the foundation is a rectangle with anintermediate wall 7 running side to side separating the foundation intoa front chamber 8 and a rear chamber 9. The concrete has openings formedas necessary for personnel access, ducts, conveyors, combustion airports, fuel injection, etc. The lower headers 10 or the lowerextremities of the tube walls 55 sit on top of the concrete foundationand in turn support the tube walls 3, 4, 25, 26, 27 and the rest of thesteel boiler structure above. The bottom of the boiler consists of oneor more V-Cell 11 and ash grate 12 installed in the foundation frontchamber 8 and suitably supported by features built into the foundation.A steel plenum duct 13 lines the four walls of the inside of foundationfront chamber 8 from the top of the foundation walls to the bottom ofV-Cells 11. V-cells 11 are preferably V-shaped, but other configurationsare within the scope of the invention. Plenum duct 13 is comprised ofinner and outer steel walls parallel to the foundation walls and spacedabout 1½″ apart with the outer walls in contact with the inside of theconcrete foundation walls that form combustion chamber 1.

At least some of the combustion air and/or recirculated flue gas fed tothe boiler flows through plenum duct 13, therefore plenum duct 13 actsas a thermal barrier between combustion chamber 1 and foundation 2 andintermediate foundation wall 7, and also as an air heater for at leastsome of the air and/or recirculated flue gas flowing to the boiler.Immediately to the inside of plenum duct 13 is a layer of thermalinsulation 14, parallel to and in contact with the inner wall of plenumduct 13. The insulating layer 14 extends around the inside of the fourwalls of plenum duct 13 and extends from the bottom of V-Cells 11 toabove the top of concrete foundation 2 and intermediate foundation wall7. Insulating layer 14 may be comprised of insulating type refractory,ceramic paper, ceramic bats, poured refractory, precast refractorytiles, or some combination of these or other suitable materials.Insulating layer 14 may be from 4 inches to 6 inches thick. Immediatelyto the inside of insulating layer 14 is a layer of working refractory15, parallel to and in contact with the inner surface of insulatinglayer 14. Working refractory layer 15 extends around the inside of thefour walls of insulating layer 14 and extends from the bottom of V-Cells11 to above the top of concrete foundation 2 and intermediate foundationwall 7. Working layer 15 may be up to 6 inches thick and the top edge ofthe four walls of working layer 15 are shaped to form a protective curb16 reposed against the boiler tube walls. Working layer 15 is comprisedof a high strength abrasion resistant refractory material with anoperating temperature limit of up to 3000 degrees Fahrenheit. Therefractory of working layer 15 also has relatively high density, highthermal conductivity, and high heat capacity. If multiple V-Cells areemployed, plenum duct 13, insulating layer 14, and refractory layer 15are extended between the V-Cells.

Referring to FIG. 4, the combustion air and/or flue gas flowing throughplenum duct 13 flows into ash chutes 56 then up through perforations inash grates 12 and then through the fuel residing in V-Cells 11 as shownby the arrows 57. FIG. 4 only shows arrows 57 on the left V-Cell forclarity, but all cells would typically be run that way. The air and/orflue gas pressure sufficient to force the air/gas up through the fuelpile is equal to the density of the fuel times the depth of the pile.This gas flow can account for up to 40% of the stoichiometric airrequirement for burning the fuel. Additional air and/or recirculatedflue gas is injected through agitation air ports 59 located three totwelve inches above the grate with a horizontal spacing of 3″ to 24″.This air/gas is injected at a relatively high pressure, 10-30 psi toagitate and loosen the fuel pile. This will help to move sand and rocksdown to the ash grate and keep the lighter fuel and carbon at thesurface. It also helps to distribute the fuel front to back and side toside after it drops from the fuel chutes at 60 and mixes combustion airand/or recirculated flue gas with the fuel to improve the drying andcombustion of the fuel. Agitating air jets 58 can be turned on or off asneeded to best achieve a preferred degree of agitation. A series ofmanual or automatically controlled valves 61 control which agitation airjets are on and off.

Referring to FIG. 5, agitation air ports 59 are arrayed above the ashgrate in a horizontal row front to back with a row of ports on bothopposing sides of the V-Cell. The horizontal separation distance betweenagitation air ports is from 6-18″. One possible configuration is to havethe agitation air ports turned on and off in an alternating pattern andopposite from side to side such that agitation air jets 58 form a sideto side interlaced crossing pattern as shown in the right hand V-Cell inFIG. 5. Agitation air jets 58 are only shown on the right V-Cell forclarity but all cells would be run in a similar manner. Some of thecombustion air and/or recirculated flue gas flowing through plenum duct13, or from other ducts, is routed through sweep air ports 45 andinjected into combustion chamber 1 from two opposing walls, (shown fromthe front and rear walls). The sweep air ports are generally arrangedwith a lower level of ports 45 a 10 to 18 inches above ash grate 12 andan upper level of ports 45 b at the top of V-cell 11. During normaloperation lower level ports 45 a are turned off or run at minimum flow(for cooling to prevent burnout of the metal sleeve lining the portopening). This allows the fuel to pile up to the level of upper sweepair ports 45 b. Sweep air jets 62 flow across the top of the fuel pileleveling out the fuel and may supply additional combustion air (inaddition to the ash grate air 57 and agitation air 58) if needed to keepthe fuel pile burning at a consistent height near the top of V-Cell 11.Typically only the upper sweep air ports 45 b on one wall will be turnedon and the corresponding ports on the opposite wall will be turned off(or at least run at minimal flow for cooling). This will allow maximumpenetration of sweep air jets 62 and maximize the effectiveness of thatair/gas. Periodically, the upper sweep air ports 45 b on opposing wallswill “flip-flop”, such that the wall that was on will turn off andvice-versa. This will ensure uniform formation of the fuel piles anduniform combustion across the top of the fuel pile. The sweep air ports45 b will flip-flop as frequently as needed to maintain consistentconditions, approximately every 15 minutes. Over-fired air ports 31,after burner airports 51, and sweep air ports 45 can all be fitted withautomated dampers 54 that can be programmed to turn on and off atprescribed intervals. This will “flip-flop” the damper settings andreverse the circulation patterns to prevent a long term bias in the fuelformation or other aspects of the boiler operation.

It is also necessary to periodically remove ash, rocks, sand, andcontaminants from the bottom of the boiler. To facilitate this theapproximately horizontal opening at the bottom of each V-Cell 11 isfitted with ash grate 12 that pivots on shaft 71 to dump the ash etc.into ash conveyor 72 below. Ash chute 56 extends below the surface ofthe ash conveyor 72 to form a pressure seal between the boiler and theoutside environment. Shaft 71 is water cooled and the water dischargesfrom the shaft through a series of holes into ash conveyor 72. Ash grate12 cannot be dumped, however, unless the fuel in V-Cell 11 above it isburned away leaving just ash and sand, etc. When it is time to dump theash, fuel flow to the V-Cell to be dumped is temporarily stopped andfuel flow to an adjacent cell is temporarily increased to partiallycompensate. Air continues to flow through the fuel via air jets 57and/or 58 and/or over the fuel at jets 62 so the fuel continues to burnaggressively. The fuel below the surface has been drying through theaction of the air/gas jets and from heat absorbed from the combustion ofthe fuel above and from burning fuel that is cycled back down into thefuel pile by agitating jets 58, and will burn very quickly when exposedand that will further compensate for the reduced fuel flow. At this timelower sweep air ports 45 a are turned on to ensure that the fuel isburned out completely before ash grate 12 is opened. The other jets 57,58, and 62 are adjusted as necessary to complete the combustion withoutblowing ash back up into the boiler. Lower sweep air jets 73 can bearranged to flip-flop to ensure complete and level combustion of theremaining fuel. After the ash is dumped grate 12 returns to the closedposition and fuel flow is restarted to the V-Cell. The residual heat inrefractory layer 15 reignites the fuel as it flows back into the V-Cell.To minimize the disturbance caused by cutting fuel flow to one entireV-Cell, each V-Cell may be divided into front and rear halves by anintermediate separating wall (not shown). The construction of theseparating wall is similar to the construction of the V-Cells. In thatcase each half of the V-Cell has an independently operating ash grate 12and independent air supplies at 57, 58, and 73.

A first purpose of the described construction around the perimeter ofcombustion chamber 1 is to promote and support much higher combustiontemperatures than current boilers. Working refractory layer 15 andinsulating layer 14 have operating temperature limits up to 2800° F. ormore as compared to bubbling fluidized bed boilers that have anoperating limit around 1600° F. The purpose of insulating layer 14 is toretain as much of the heat of combustion as possible in the combustionchamber, without transmitting that heat to adjacent boiler walls, as inconventional boilers, or to the adjacent supporting structures ofembodiments of the present invention. This will increase the temperaturein the combustion chamber and allow the firing of wetter fuel. This alsoallows a significant reduction in the plan area of the boiler as theheat release is concentrated in a smaller area. This in turn reduces theoverall size of the boiler and makes the boiler much less expensive tomanufacture and erect. This gives embodiments of the present invention asignificant economic advantage over other boilers that generate similaramounts of steam with similar fuels. Insulating layer 14 minimizes heattransfer out of combustion chamber 1 and working refractory layer 15provides protection to insulating layer 14. While insulating layer 14has low thermal conductivity, some heat will still be transmittedthrough it therefore plenum duct 13 is desirable for preventingoverheating of concrete foundation 2 and intermediate foundation wall 7.A second purpose of the construction is to act as a heat sink around thecombustion chamber. Working layer 15 has a relatively high heatcapacity; therefore it will retain a lot of heat. If the temperaturedrops in combustion chamber 1, due for example to a batch of overly wetfuel, the heat contained in working layer 15 will be radiated tocombustion chamber 1 where it will help to dry and ignite the wet fueland stabilize the combustion process. Working refractory layer 15, inother words, acts as a thermal flywheel.

Referring back to FIGS. 1 and 2, fuel bin 63 is situated on top of, andsupported by the boiler. The bin has a live-bottom, that is, it hasconveying screws 64 that fill a majority of the floor area of the bin,substantially reducing the possibility of plugging in the fuel bin. Manyarrangements are possible but in the configuration shown, two parallelscrews feed each fuel chute. The screws are split into left and rightpairs corresponding to each fuel chute with the speed of each pairindependently adjustable. Therefore the feed rate to each fuel chute isindependently adjustable. The advantage of this arrangement is that itmay reduce the number of conveyors used to get fuel to the boiler andimprove the response of the boiler to load changes as there is no lag ingetting fuel to the boiler. There are two versions of fuel chutes shownbut typically one or the other version would be used. On the left ofFIG. 2 fuel drops from conveying screws 64 through drop chute 66 anddrops through fuel chute 22 comprised of upper chute 20 and lower chute21 and then falls into the boiler at 60. The exterior walls of eachupper fuel chute 20 are comprised of boiler tubes making a three sidedchute, integral with the side wall of the boiler, with the interior ofthe chutes 20 open to front pass 5 (the interior of boiler). Theexterior walls of each lower fuel chute 21 are comprised of reinforcedconcrete and form a three sided chute with the interior of the chutes 21open to the interior of combustion chamber 1. The interiors of chutes 22are lined with insulating layer 17 and working refractory layer 18 asshown. In FIGS. 1, 2, and 3, refractory tiles 23 are stacked one aboveanother across the openings between upper fuel chutes 20 and theinterior of the boiler 5, and across the openings between lower fuelchutes 21 and the interior of combustion chamber 1. Refractory tiles 23serve to retain the fuel as it is falling through the chute and also toradiate heat absorbed from the front pass 5 and combustion chamber 1 tothe falling fuel. The stack of refractory tiles 23 ends below the top ofupper fuel chute 20 and above the bottom of fuel chute 21 leaving apassageway for combustion gasses to flow into the top of upper fuelchute 20 and out the bottom of lower fuel chute 21. The opening at thebottom of lower fuel chute 21 also allows the passage of the fuel intocombustion chamber 1. Alternately refractory tiles 23 can be replacedwith cast refractory. The hot combustion gas and/or radiant heat fromrefractory tiles 23 produces a drying effect on the falling fuel. Thefuel chutes described above are more specifically detailed in U.S.patent application Ser. No. 12/471,081 and 61/522,939. On the right ofFIGS. 2 and 3 a second version of the fuel chute 68 incorporates threesided refractory walls 65 located entirely inside the boiler. Theadvantage of this design is that it minimizes the number of wall tubes,is easily adaptable to an existing boiler, and increases the radiantheat transfer surface as three sides of each fuel chute 68 are exposedto the heat of combustion. The refractory comprising walls 65 may bepre-cast and pre-fired or it may be poured in place. In this version,conveying screws 64 discharge into drop chute 67 which then pass througha suitably formed opening in the tube wall. Drop chute 67 dischargesinto fuel chute 68 which is open at the top 69 and bottom 70. The fuelfalling through the chute, and the reduction of temperature (increasingdensity) will induce a flow of hot combustion gas in at 69 and out at70. The hot gas will further increase the drying of the fuel in thechute. Chute 68 may be designed to increase in cross sectional area asthe fuel descends to minimize the potential for plugging the chute.

The outer boiler walls 3, 25, 26, 27 and intermediate boiler wall 4 aresupported by foundation walls 2 and intermediate foundation wall 7 andmay rise vertically to a height up to 80 feet or more above the ground.Interior to front pass 5 are multiple chamber walls 24 constructed ofsimilar steel tubes to the boiler walls with the tubes side by side inclosely spaced parallel configuration forming flat panels. The chamberwalls 24 as shown in FIGS. 1, 2, and 3 are parallel to the front wall ofthe boiler and are spaced more or less evenly between front wall 3 andintermediate wall 4. The Chamber walls can alternatively be parallel tothe sidewalls. The lower extremities of the tubes forming chamber walls24 pass through the side walls 25 and 26, with half of the tubes formingeach chamber wall coming in through left wall 25 and half through rightwall 26. The tubes comprising one half of each chamber wall 24 passthrough side walls 25 or 26 horizontally or with a slightly upward angleas they extend toward the middle of front pass 5. The more or lesshorizontal tubes are arrayed with one tube immediately above another sothat all of the tubes forming half of one chamber wall 24 can passthrough sidewall 25 or 26 between two wall tubes that have been bentapart for that purpose. When the two sets of tubes forming each half ofthe chamber walls 24 meet in the middle of the boiler, they turn upwardand form a single panel that continues vertically and finally exitsthrough the roof of the boiler. Chamber walls 24 are narrower than thewidth of the boiler such that gaps 28 exist between the outside edges ofchamber walls 24 and left sidewall 25 and right sidewall 26. In somecases, over-fired air ports 31 are formed in sidewalls 25 and 26 toinject combustion air and/or recirculated flue gas between chamber walls24. The arrangement of over-fired air ports 31 is typically one to threehorizontal rows of ports 30 with each port in each row locatedapproximately centered in the gap between chamber walls 24. Verticalseparation between air port rows 30 can be 3 feet to 10 feet. Gaps 28allow for circulation of combustion gasses around and between chamberwalls 24. Over-fired air ports 31 are fitted with automated dampers 54that can be programmed to turn on and off in unison and at prescribedintervals. This will “flip-flop” the damper settings to prevent a longterm bias in the gas flow, heat transfer, tube fouling patterns, ashaccumulation or other aspects of the boiler operation. FIGS. 1 and 3show six chamber walls 24 but the number may vary depending on the sizeof the boiler and how much surface area is needed for heat transferpurposes.

Chamber walls 24 are made as tall as practical with the lowerextremities just above the refractory walls 15 of combustion chamber 1and extending up through the roof of the boiler 32. The lower ends ofchamber walls 24 are fed by downcomer pipes (not shown) from steam drum43 that feed relatively cold water to vertical headers 40 that in turnfeed the individual tubes forming chamber walls 24. At the top of frontpass 5, some of the tubes comprising chamber walls 24 are bent out ofthe plane of the chamber walls to form front to back passageways for thecombustion gasses to pass through and exit to the rear of front pass 5.These are chamber wall screens 39. At this point the gasses stop flowingup and/or around the chamber walls and pass through chamber wall screens39 to exit the front pass. Similarly, some of the tubes at the top ofintermediate wall 4 are bent out of the plane of the wall to form rearscreen 41. The vertical location of the cluster of over-fired air ports31 within front pass 5 can be from just above V-Cells 11 to the top ofthe boiler depending on the application. For example, if the boiler isburning a light fuel such as bagasse or straw based fuels, over-firedair ports 31 may be preferentially located at a higher elevation. Lightfuels tend to create a lot of fly ash that may not burn before leavingthe furnace. By locating over-fired air ports 31 at a higher elevation,those fly ash particles have more opportunity to burn out before a finalturbulent mixing with additional combustion air to assure their completecombustion. After chamber wall screens 39 and rear screen 41 passthrough boiler roof 32 the tubes are bent back into the plane of chamberwalls 24 and intermediate wall 4, respectively, and then terminate incollecting headers that are in turn connected back to steam drum 43. Asthe water in chamber walls 24 is heated it expands and becomes lessdense and the heavier cold water flowing down from steam drum 43 pushesthe hotter and lighter water upward creating a natural circulationthrough chamber walls 24.

Chamber walls 24 are arranged in a similar manner as screens inconventional boilers in that they are located in the front pass of theboiler and comprise some of the water circulation circuits of theboiler. The chamber walls are novel, however, in that they extend muchlower in the boiler, can be arranged parallel to the front wall, aresymmetrical in their arrangement, and are arranged so that combustiongasses can circulate around them. The chamber walls are also meant totake the place of the generating bank in conventional boilers thereforeboiling will occur in the upper portion of chamber walls 24. The lowerportion of chamber walls 24 are filled with water and therefore will beheld close to the saturation water temperature. This prevents chamberwalls 24 from over-heating at their lower extremities where thecombustion gasses are hottest. The high differential temperature betweenthe gasses leaving combustion chamber 1 and the surface of the lowerportion of chamber walls 24 will create a high heat flux from thecombustion gases to the water in the chamber wall tubes. This willrapidly reduce the temperature of the combustion gasses as theycirculate around and rise past chamber walls 24 and will preventoverheating the chamber wall tubes even as the water is boiling at theupper ends of the tubes.

After flowing up and around chamber walls 24 and through chamber wallscreens 39, the combustion gasses pass through rear screen 41 and enterback pass 6 where the gasses turn and flow vertically down over thesuperheaters 50. In some cases, a series of after-burner air ports 51may be located below rear screen 41 and above superheaters 50 to injecta final amount of combustion air to complete the combustion of anysyn-gas remaining in the flue gas stream. This can provide a means forcontrolling the steam temperature in the superheaters. The arrangementof after burner ports 51 may be in one or more levels with one or moreports at each level with the ports aligned to create interlaced orcirculating gas flow patterns depending on the spacing of the ports orthe setting of the control dampers. Automated dampers can be installedand programmed to control the flow pattern and periodically flip-flopthe arrangement as described above for sweep air ports 45 and over-firedair ports 31. One or more gas or oil burners 82 may be installed at thislocation to ensure ignition of the cooled flue gas or to control finalsteam temperature by controlling the temperature of the flue gasentering the superheaters. The installation and arrangement ofover-fired air ports 31 and after burner ports 51 depends on manyfactors including fuel type, emissions requirements, boiler loading,downstream processes, etc. For example, over-fired air ports 31 may bemoved up or down in front pass 5 to fit specific requirements, or may beomitted altogether in favor of after burner ports 51, and vice versa.

The tubes forming superheaters 50 run horizontally back and forth acrossrear pass 6, either front to back or side to side. They can be arrangedin a rectangular pattern with one tube above another but preferablyarranged in a staggered pattern in which the combustion gas has to flowaround all of the tubes. The latter arrangement is more thermallyefficient but can be more difficult to clean. Being more thermallyefficient, the staggered arrangement requires fewer tubes therebyreducing the cost of the boiler. Another feature of superheaters 50 areinternal tube sheets 52 that channel the flue gasses across only thestraight sections of the tubes. It is common that particulates in theflue gas stream preferentially erode the tubes at the bends thereforetube sheets 52 shield the tube bends and prevent their erosion. Thereare at least four significant advantages to the location of superheaters50 in rear pass 6. First, as the superheaters are located downstreamfrom chamber walls 24, chamber wall screens 39, and rear wall screen 41,the flue gas temperature entering superheaters 50 will be lower than ifthe superheaters were located in front pass 5 as is common practice.This will help prevent corrosion of the superheater tubes from chloridespresent in the flue gas if, for example, the boiler is used toincinerate municipal waste containing plastic. A second advantage iswater can be used to clean the superheater tubes as there is no dangerof water interfering with the combustion process. This allows tighterspacing of the superheater tubes which can compensate for lower flue gastemperature and/or reduce the overall surface area of the superheater. Athird advantage is that the location lends itself to reheating thecombustion gasses (either with additional combustion air or auxiliaryburners as described above) to provide steam temperature controlindependent from the combustion requirements in the front pass. A fourthadvantage is that the location in the back pass lends itself tomodularizing the superheaters as described below. Superheaters inconventional boilers are typically placed at the top of the boiler abovethe bullnose and arranged with the combustion gas in cross flow. Thesuperheater platens are typically spaced 7-12″ or more apart to minimizethe potential to plug between the platens. This wide spacing increasesthe superheater surface area and the volume (furnace size) to enclosethe superheaters.

Embodiments of the present invention improve on previous technology bylowering the amount of capital employed and improving the operation ofpower boilers. Chamber walls 24 and intermediate wall 4 replace atypical generating bank but are widely spaced therefore, like boilerwalls 3, 25, 26, and 27, are not prone to plugging. Chamber walls 24 andintermediate wall 4 are water filled; therefore the metal is moreprotected by being held at a lower temperature than superheaters. Thechamber walls are exposed on both sides to the hot combustion gasses andthe combustion gasses are in more intimate contact with chamber walls 24and intermediate wall 4 than outside walls 3, 25, 26, and 27 thereforethey will transfer much more heat than the outside boiler walls. Thislarge heat transfer rate collapses the gas temperature quickly so thatby the time the gas enters back pass 6 the gas temperatures are lowerthan in a conventional boiler. This makes any accumulated materialeasier to remove and creates an opportunity to control the gastemperature in back pass 6 by the introduction of additional combustionair through air ports 51. Chamber walls 24 also scrub ash andparticulates from the combustion gas flowing through the boiler. Thesuspended ash and particulates will tend to stick to the surfaces theycontact (until they accumulate sufficiently and are eventually shed orblown off by sootblowers) so the gasses will deposit a large part of thesuspended material on chamber walls 24 before the gasses enter back pass6. Chamber wall screens 39 and rear wall screen 41 are widely spaced andcombined with the lower gas temperature and less particulates, will bemuch easier to clean by sootblowers located adjacently. So the chamberwalls are advantageous compared to a generating bank because theycollapse gas temperature, trap particulates yet are easier to clean,reduce the boiler volume, improve heat transfer rates, and reduce theoverall cost of the boiler.

Superheaters 50 located in back pass 6 are in cross flow arrangement (asin a conventional boiler) but because much of the particulates have beentrapped out by chamber walls 24, the tubes can be more closely spaced,even in a staggered arrangement, improving the heat transfer efficiency.Due to the lower gas temperature in back pass 6, more surface area maybe needed in superheaters 50 but this is offset by the more efficienttube arrangement and the improved cleanliness of superheaters 50. Withthe superheaters 50 located in the back pass, and with lower gastemperature, the tubes can be cleaned more effectively with conventionalsootblowers or even periodically with water. This ensures much cleanertube surfaces and allows for a reduction in the surface area of thetubes as well as an overall reduction in the size of the boiler. Withless particulates reaching the superheaters and lower gas temperature,less steam may be used to clean the superheaters when using conventionalsootblowers, lowering the operating cost of the boiler. Also, the tubescomprising superheaters 50 are all the same length (as opposed totapered pendants in a conventional boiler) allowing more economicalfabrication. Embodiments of the present invention also have theadvantage of being ground supported. Conventional large power boilersare suspended from overhead with the thermal expansion more or lesscentered at the steam drum. As described above, embodiments of thepresent invention can be much smaller than a conventional boiler for thesame load rate and with intermediate wall 4 the construction is veryrigid. Therefore the boiler can support the weight of steam drum 43 andit can move up and down with the boiler expansion. This eliminates theneed for a very strong building surrounding the boiler. So embodimentsof the present invention are less expensive to build and operate and runbetter than a conventional boiler of the same load rate.

Finally, embodiments of the present invention may incorporate modularconstruction to facilitate on-site erection. Referring now to FIG. 3, ifthe boiler is sized to produce 120 tons of steam per hour, the width ofthe boiler (centerline distance from left sidewall 25 to right sidewall26) may be about 16 feet, the depth of the front pass (centerlinedistance from front wall 3 to intermediate wall 4) may be about 19 feet,and the depth of the rear pass (centerline distance from intermediatewall 4 to rear wall 27) may be about 10 feet. Embodiments of theinvention that are approximately this size may be constructed in sixsections as shown divided by lines 74-74, 75-75, and 76-76. Front pass 5may be divided into quadrants and rear pass 6 may be divided intohalves. Each quadrant of front pass 5 may be fabricated as anindependent module containing half of sidewall 25 or 26, half of frontwall 3 or intermediate wall 4, and part of the roof of the boiler. Eachquadrant module also may contain the portion of chamber walls 24 thatreside in that quadrant. Each of these modules may be prefabricated withinlet and outlet headers, fuel chutes, buckstays, port openings,ducting, connection points, lifting points, supports, etc. as could beinstalled at the factory. Each module may be pressure tested at thefactory potentially resulting in fewer bad welds in the field andpotentially reducing non-destructive testing time in the field. Theinlet and outlet headers may be fabricated in halves and may remainindependent after the boiler is erected to eliminate the need to fieldweld and heat treat those large diameter pipes. Referring to FIG. 1, ineach of the two front-most modules of front pass 5, the tubes comprisingfront wall 3 may bend over at the top of the boiler to form roof tubes32 terminating in relieving header 77. Header 77 may be divided in twoindependent halves, each half connected to its respective module.Similarly, the tubes comprising intermediate wall 4 may bend over at thetop to form roof tubes 78 terminating at relieving header 79, alsodivided into two independent halves. Each half of rear pass 6 may besimilarly fabricated as an independent module containing half of thesuperheaters. Rear tubes forming rear wall 27 may bend over at the topto form rear pass roof 80 and terminating in relieving header 81, alsodivided into independent halves. Each of these modules may be sized toallow transportation by truck with a maximum size of approximately 12feet by 10 feet by 60 feet. Modules of this size and construction mayweigh up to 75,000 pounds which is well within the lifting capacity ofcommon mobile cranes. V-Cells 11 and combustion chamber 1 may also beprefabricated as much as possible including insulating and refractorycomponents where practical. The erection sequence may start with theconcrete foundation which is poured on site. Then the boiler modules arelifted into their respective positions one at a time. As the modules areset in place, they are bolted and/or welded together at strategiclocations to hold the modules in alignment. In particular, the buckstays(not shown), prefabricated with each module, are bolted together to holdthe modules together. When each module is in place, and the alignment isconfirmed, each module is seal welded to the adjacent modules. When allboiler modules are in place the combustion chamber and V-Cell modulescan be installed. When the boiler modules are welded together, the steamdrum can be lifted in place. The pressure parts are completed byconnecting the feed and relieving headers to the steam drum viaintermediate pipes (not shown for clarity). Finally, all of theauxiliary equipment can be installed such as the fuel bin, fuel screws,ducting, fans, ash grate, ash conveyors, pumps, piping, platforms, etc.Furthermore, it is not necessary to erect a large building to supportthe boiler before the boiler construction can begin. The groundsupported, modular design of embodiments of the invention will greatlyspeed up the field erection process and greatly reduce the temporal andfinancial uncertainties commonly associated with that phase of boilerconstruction.

An alternative embodiment of the present invention is used as agasifier. As a gasifier, fuel enters the boiler in the same manner asdescribed in the first embodiment, but is burned in sub-stoichiometricconditions and only to the extent desirable for maximizing theproduction of syn-gas. Refractory lining 15 and insulating lining 14absorb much heat of combustion in combustion chamber 1 promotinghigh-temperature fuel gasification. If the gasifier is operatedpredominately as a syn-gas producer, it is preferred to inject pureoxygen to minimize the syn-gas dilution from nitrogen. In that case, theoxygen can be injected through agitation air ports 59 to agitate thefuel piles and inject oxygen directly into the fuel. Only enough oxygenis injected to produce the concentrated syn-gas production targets.Grate air 57 and sweep air 62 can also be adapted to inject oxygen tomaintain and control the temperature in combustion chamber 1. It isimportant to reduce the temperature of the syn-gas before it is pulledoff the boiler so that it can be handled, cleaned, and acid gases (CO₂,H₂S, COS) removed. Chamber walls 24 will be very effective in reducingthe gas temperature before it leaves the boiler. Over-fired air ports 31may not be required and the syn-gas may leave the boiler just downstreamfrom rear screen 41. As a gasifier the boiler will be configured toproduce saturated steam at a rate proportional to the heat released butnot used by the gasification process. If production of superheated steamis desirable, some of the syn-gas may be allowed to flow into back pass6 where after burner ports 51 can inject air to burn those gases tosuperheat the steam. Alternately a separate fuel, such as natural gas,can be burned at the location of afterburner ports 51 to superheat thesteam. If production of superheated steam is not desired, back pass 6and superheaters 50 may not be required.

In accordance to some embodiments of the present invention, the floor ofa solid fuel fired boiler may be configured as one or more troughs inwhich most of the fuel firing the boiler falls into the troughs andburns therein, where each of the troughs comprises an outer supportingstructure, an inner refractory layer, and an insulating layer betweenthe outer supporting structure and the inner refractory lining.

In some embodiments, the outer supporting structure comprises a ductsystem configured to convey combustion air, oxygen, or recirculatedboiler flue gas, or any combination thereof, to the combustion chamberof the boiler.

In some embodiments, the bottoms of each of the troughs are truncatedresulting in approximately horizontal openings in the bottoms of each ofthe troughs, and in which a chute means extends downwards from each ofthe openings and a perforated movable grate floor resides below each ofthe openings such that each of the movable grate floors may be openedperiodically to discharge the contents of each of the troughs.

In some embodiments, combustion air, oxygen, or recirculated boiler fluegas, or any combination thereof, may be injected below each of theperforated movable grate floors and then flows up through each of theperforated movable grate floors.

In some embodiments, each of the perforated movable grate floors issupported by a rotatable shaft, and each of the floors opens by rotatingeach of the shafts.

In some embodiments, each of the rotatable shafts is water cooled.

In some embodiments, an agitating gas comprising air, oxygen,recirculated boiler flue gas, or any combination thereof, may beinjected through agitation air ports located within one or more sides ofeach of the trough or troughs in a manner sufficient to agitate andloosen the fuel residing therein, and wherein the flow and/or pressurethrough any agitation gas port may be adjusted independently of anyother agitation gas port.

In some embodiments, one or more sweep air ports may be located abovethe agitation air ports, where these sweep air ports would be configuredto inject jets of air, oxygen, recirculated boiler flue gas, or anycombination thereof, in a manner to sweep across the top of the fuellevel, and wherein any established sweep air flow pattern may beperiodically reversed.

In some embodiments, the troughs in the boiler floor may be separated byan intermediate wall or walls of similar construction as the boilerfloor.

In accordance to some embodiments of the present invention, a solid fuelfired boiler may be configured with one or more walls internal to thefurnace section of the boiler, where each of the walls could compriseclosely spaced steel tubes in mutually parallel relationship and alignedsuch that the axes of the tubes are vertical for the majority of theirlength, with the tubes comprising one or more water and/or steamcirculation circuits within the boiler.

In some embodiments, the boiler may be configured with an outersupporting structure lined with insulation, and wherein the insulationis lined with a refractory material.

In some embodiments, an air plenum may be located between the insulationand the supporting structure.

In some embodiments, one or more fuel chutes may be configured integralwith one or more exterior walls of the boiler in which fuel flowingthrough the chute or chutes is directly exposed to hot boiler gas or tothermal radiation from one or more surfaces of the fuel chutes which areheated by the hot boiler gas to effect partial drying of the fuel.

In some embodiments, one or more of the fuel chutes may be configuredwith three sides internal to the furnace.

In some embodiments, the boiler may be configured with a front pass anda back pass, wherein the back pass comprises a superheater andcombustion air ports configured to complete the combustion of volatilegasses and/or control the temperature of the steam exiting saidsuperheater.

In some embodiments, oxygen may be used to cause combustion of a portionof the fuel therein, wherein the heat released by this combustion maycause gasification of the remaining fuel.

In some embodiments, the boiler may be constructed with one or moreinternal tube walls configured to rapidly cool said gasified fuel.

In some embodiments, the boiler may comprise oil or gas fired burnerslocated within the back pass and configured to control the temperatureof the steam exiting the boiler.

In accordance to some embodiments of the present invention, a solid fuelfired boiler has a fuel bin located on top with a multiplicity of fuelchutes configured to conduct fuel to a furnace of the boiler, whereinthe majority of the floor area of the fuel bin comprises conveyingscrews configured to feed fuel at a controlled rate from the fuel bin toeach of the multiplicity of fuel chutes, wherein each of the conveyingscrews is configured to convey fuel at an independently-controllablerate to the furnace of the boiler.

In some embodiments, the boiler is configured with a multiplicity ofmodules, and the boiler may be assembled from these modules on-site at adesired operating location for the boiler.

In some embodiments, one module incorporates any combination of at leastpart of the front wall, at least part of a side wall, at least part ofthe roof, and at least part of the internal wall or walls of the boiler.

In some embodiments, one module incorporates any combination of at leastpart of the rear wall or rear wall of a front pass, at least part of aside wall, at least part of the roof, and at least part of the internalwall or walls of the boiler.

In some embodiments, at least one module incorporates any combination ofat least part of a rear wall, at least part of a side wall, at leastpart of the roof, and at least part of the superheaters of the boiler.

In accordance to some embodiments of the present invention, a method ofoperating a solid fuel fired boiler comprises the steps of loading fuelinto a fuel bin located at the top of the boiler; conveying the fuelfrom the bottom of the fuel bin into the entrance of a conveying screw;transferring fuel from the entrance of the conveying screw to the exitof the conveying screw by means of rotary motion of the conveying screw;loading the fuel into the top of the fuel chute from the exit of theconveying screw into the top end of a fuel chute; and dropping fuel downthe fuel chute to a furnace of the boiler.

In some embodiments, the rate of transfer of fuel from the entrance tothe exit of the conveying screw is controlled by the rotational rate ofthe screw.

In some embodiments, a multiplicity of conveying screws enableindependent control of the rate of fuel transfer from the fuel bin toeach of a multiplicity of fuel chutes.

In some embodiments, a furnace construction process for a solid fuelfired boiler, comprises the steps of configuring an outer supportstructure to generally define the dimensions of one or more cells in thefurnace; lining the support structure with insulating material; liningthe insulating material with refractory material; and configuring one ormore fuel chutes to convey fuel into each of the one or more cells inthe furnace.

In accordance to some embodiments of the present invention, a method ofconstructing a solid fuel fired boiler comprises the steps ofconfiguring a furnace in one or more cells, where each cell comprises anouter support structure; an insulator layer lining the supportstructure; and a refractory layer lining the insulator layer;positioning an array of chamber walls above the furnace for generationof steam, wherein each wall comprises a generally vertical array ofapproximately parallel steam-generating tubes; and locating at the topof the boiler a fuel bin, comprising a floor largely comprised of a oneor more fuel-conveying screws.

A boiler as described herein has many aspects believed to be novel. Thefurnace may be subdivided into one or more V-cells, each lined withinsulation and refractory material. The insulation allows the refractorymaterial to retain heat, acting as a “thermal flywheel”, therebysmoothing out variations in the furnace temperature which mightotherwise arise due to changes in the water content of the fuel. Thisrefractory material also allows higher furnace operating temperatures,thereby enabling the use of wetter fuels and higher fuel combustionefficiencies. A fuel bin is positioned above the boiler assembly with alive bottom comprising a number of conveying screws which directlytransfer fuel from the fuel bin to a multiplicity of fuel chutes, eachof which, in turn, conveys fuel directly to the furnace. This fuelsupply mechanism enables rapid variation in the rate of fuel feed downeach of the chutes to allow for quick adjustments in the rate of fuelsupply to each V-cell in the furnace. Alternative fuel chute designs arepossible within the scope of the invention. In some fuel chute designs,three walls of each fuel chute are directly heated by the hot combustiongases, and this heat may then be transferred to the falling fuel beforeit reaches the furnace. The conventional steam generating bank isreplaced by an array of chamber walls, each comprising a large number ofapproximately vertical parallel steam-generating pipes which extenddownwards to near the top of the furnace, and upwards to near the top ofthe boiler. Advantages of this chamber wall design include improved heattransfer between the combustion gases and the pipes in the chamber wall,reduced gas temperatures exiting the front pass of the boiler, widerpipe spacings to reduce potential boiler plugging, and the ability toposition the chamber walls parallel to the front of the boiler. Theboiler is partitioned into front and rear passes, with the superheaterpiping located in the rear pass and not directly in the upward verticalflow of combustion gases from the furnace. This configuration has theadvantage that the temperature of the superheated steam can beindependently controlled, the gases passing over the superheater tubesare at a lower temperature thus reducing corrosion, water cleaning ofthe superheater tubes is possible since the water will not fall into thefurnace, and the superheater tubes may be spaced closer together sincecleaning is easier. Other advantages of the front/rear pass design arean improved ability to control the gasification process, including theintroduction of oxygen to reduce nitrogen contamination of the syn-gas,and the use of additional burners to regulate gas temperatures withinthe rear pass independently of gas temperatures within the front pass.Bed-fired water tube boilers employing a design according to aspects ofthe present invention may be more compact than conventional solid fuelburning boilers, thus a ground-mounted approach may be adopted, avoidingthe need for robust construction techniques required for hung-boilerdesigns. The present invention facilitates the use of modular designapproaches in which the boiler may be fabricated in multiple sections ata factory off-site, and subsequently transported in pieces to thelocation on-site at which the boiler is to be fully-assembled andoperated. This potentially enables substantial cost and time savings forboiler installations compared with conventional boiler design andassembly approaches.

Although embodiments of the present invention and their advantages aredescribed in detail above and below, it should be understood that thedescribed embodiments are examples only, and that various changes,substitutions and alterations can be made herein without departing fromthe spirit and scope of the invention as defined by the appended claims.The scope of the present application is not intended to be limited tothe particular embodiments of the process, machine, manufacture,composition of matter, means, methods and steps described in thespecification. As one of ordinary skill in the art will readilyappreciate from the disclosure of the present invention, processes,machines, manufacture, compositions of matter, means, methods, or steps,presently existing or later to be developed that perform substantiallythe same function or achieve substantially the same result as thecorresponding embodiments described herein may be utilized according tothe present invention.

We claim as follows:
 1. A floor of a solid fuel fired boiler comprisingone or more cells in which most of the fuel firing said boiler fallsinto said cell or cells and burns therein, each of said cell or cellshaving sloping sides and including an outer supporting structure, aninner refractory layer, and an insulating layer between said outersupporting structure and said inner refractory lining, and wherein thebottoms of each of said cell or cells are truncated resulting inopenings in the bottoms of each of said cell or cells, and a movablegrate floor resides below each of said openings such that each of saidmovable grate floors may be opened periodically to discharge thecontents of each of said cell or cells; further comprising a plenum fromwhich combustion air, oxygen, or recirculated boiler flue gas, or anycombination thereof, is injected from below each of said movable gratefloors and then flows up through each of said movable grate floors; andin which each of said movable grate floors is supported by a rotatableshaft, and each of said floors opens by rotating each of said shafts. 2.The boiler floor of claim 1 in which said outer supporting structurecomprises a duct system configured to convey combustion air, oxygen, orrecirculated boiler flue gas, or any combination thereof, to thecombustion chamber of said boiler.
 3. The boiler floor of claim 1further comprising a plenum from which combustion air, oxygen, orrecirculated boiler flue gas, or any combination thereof, is injectedfrom below each of said movable grate floors and then flows up througheach of said movable grate floors.
 4. The boiler floor of claim 1 inwhich each of said shafts is water cooled.
 5. The boiler floor of claim1 further comprising agitation air ports located within one or moresides of each of said cell or cells, through which an agitating gascomprising air, oxygen, recirculated boiler flue gas, or any combinationthereof, is injected in a manner sufficient to agitate and loosen thefuel residing therein, and wherein the flow and/or pressure through anyagitation air port may be adjusted independently of any other agitationair port.
 6. The boiler floor of claim 5, further comprising one or moresweep air ports located above said agitation air ports, said sweep airports injecting jets of air, oxygen, recirculated boiler flue gas, orany combination thereof, in a manner to sweep across the top of saidfuel level, and wherein any established sweep air flow pattern may beperiodically reversed.
 7. The boiler floor of claim 1 in which saidcells are separated by an intermediate wall or walls of similarconstruction as said boiler floor.
 8. The boiler floor of claim 1 inwhich each of said cell or cells has a V-shaped cross section.
 9. Theboiler floor of claim 1 further comprising a chute extending downwardfrom each of the openings.
 10. The boiler floor of claim 1 in which saidmovable grate floor comprises a perforated moveable floor grate.
 11. Theboiler floor of claim 1 further comprising a plenum duct extending alongthe walls of said one or more cells.
 12. The boiler floor of claim 11 inwhich the plenum is positioned between inner refractory layer and theinsulating layer.
 13. A method of constructing a solid fuel fired boilercomprising: configuring a furnace in one or more cells, each comprising:an outer support structure; an insulator layer lining said supportstructure; and a refractory layer lining said insulator layer; whereinthe bottoms of each of said cell or cells are truncated resulting inopenings in the bottoms of each of said cell or cells, and a movablegrate floor resides below each of said openings such that each of saidmovable grate floors may be opened periodically to discharge thecontents of each of said cell or cells; in which each of said movablegrate floors is supported by a rotatable shaft, and each of said floorsopens by rotating each of said shafts positioning an array of chamberwalls above said furnace for generation of steam, wherein each wallcomprises a generally vertical array of approximately parallelsteam-generating tubes; and locating at the top of said boiler a fuelbin, comprising a floor including one or more fuel-conveying screws. 14.The method of claim 13 in which configuring a furnace in one or morecells includes configuring a furnace in which each of the cells includesside walls that slope towards an opening above a movable grate floor.15. The method of claim 13 in which configuring a furnace in one or morecells includes configuring a furnace in which each of the cells includesconfiguring a V-shaped cross section.
 16. A solid fuel boiler includinga boiler floor comprising one or more cells in which most of the fuelfiring said boiler falls into said cell or cells and burns therein, eachof said cell or cells having sloping sides and including an outersupporting structure, an inner refractory layer, and an insulating layerbetween said outer supporting structure and said inner refractorylining, and wherein the bottoms of each of said cell or cells aretruncated resulting in openings in the bottoms of each of said cell orcells, and a movable grate floor resides below each of said openingssuch that each of said movable grate floors may be opened periodicallyto discharge the contents of each of said cell or cells furthercomprising a plenum from which combustion air, oxygen, or recirculatedboiler flue gas, or any combination thereof, is injected from below eachof said movable grate floors and then flows up through each of saidmovable grate floors; and in which each of said movable grate floors issupported by a rotatable shaft, and each of said floors opens byrotating each of said shafts.
 17. The solid fuel boiler of claim 16further comprising a concrete foundation supporting said one or morecells.
 18. The solid fuel boiler of claim 16 in which the concretefoundation includes foundation walls that support tube walls.